Whether you look after a manufacturing plant, a crane business, a recycling plant, or building services in one of Melbourne’s sky scrapers, choosing the right hydraulic pump really matters.

The tricky part is knowing what hydraulic pumps actually do, and which style is going to play nicest with your machine, your environment, and the performance you’re chasing.​  We outline the three different types, and which will work best with your machines.

Start with the basics

Before you get into specific pump types, it helps to nail down what your hydraulic system really needs.​  These basics give you a shortlist, and help you avoid buying something that fights with the rest of your setup.​

Flow rate

Flow rate (LPM) is what decides how fast your system moves.​  Work out the maximum amount of oil you need when everything is running at once—for example, boom, arm, and bucket all moving together on an excavator.​   Go too small and everything feels slow and unresponsive; go too big and you burn extra fuel or power for no real gain.​

Pressure

Different jobs run at very different pressures.​   A simple lifting setup might be happy around 1,500 PSI, while heavier construction gear may need 3,000 PSI or more.​  Check the manuals and spec plates so you know the highest working pressure the system will see.​  Keep in mind that pressure needs change with the load—something like a forestry machine on a steep hillside will see very different demands compared to a steel wire cutting machine in a plant.​

Fluid compatibility

Pumps are not “one fluid fits all.”​  Some are built around standard petroleum-based hydraulic oil, others are tuned for biodegradable or fire-resistant fluids.​  Match your fluid spec to the pump’s compatibility charts, paying attention to viscosity, temperature range, and chemistry.​

Main pump types

Once you know what your system needs, you can start matching those requirements to the common pump designs.​   Each style has its strengths and trade-offs.

1.    Gear pumps

Gear pumps are the non-assuming work horses of the pump world.  They use a pair of intermeshing gears to move oil from the inlet to the outlet.​  They’re about as simple and rugged as it gets, which is why they show up everywhere.​  They’re a solid choice for low to medium pressure work, often up to around 2,500 PSI.​  And because of their straightforward build, they tend to tolerate dirtier oil better than more delicate designs—handy in applications where perfect cleanliness is hard to maintain.​  They’re also usually budget-friendly, easy to service, and parts are common, though they do tend to be noisier and can’t reach the same pressures as more advanced pump types.​

2.    Vane pumps

Vane pumps use sliding vanes in a rotor to create little chambers that grow and shrink as the rotor turns, giving you a smooth, almost ripple-free flow.​  That smoothness makes them a good fit for medium-pressure systems where consistent movement is important and quiet operation is required.   They can be quite efficient across their working range, so they’re common in mobile systems that need steady, controlled motion.​

The trade-off is that they’re fussier about oil cleanliness, and there are more moving parts to look after, which can cost you a little more in maintenance cost.​

3.    Piston pumps

Piston pumps use one or more pistons cycling back and forth to generate flow, and sit at the top of the tree for pressure capability and efficiency.​   There are a few different varieties of piston pumps:

1.      Radial piston pumps

• These pumps arrange the pistons in a ring around a central cam.​

• They shine in high-pressure, low-flow jobs—think industrial presses or molding machines—where you need very accurate pressure control and long life.​

2.      Axial piston pumps

• Here the pistons run parallel to the drive shaft, working off a swash plate or bent axis to create the reciprocating motion.​

• They can cover a wide range of pressures and flows efficiently, which is why they’re so common in construction, ag gear, and industrial systems.​

• Many are variable-displacement, so you can adjust flow without chasing engine speed, which opens the door to serious energy savings when loads and demands are always changing.​

3.      Servo pumps

Servo pumps essentially combine a piston pump with tight electronic control.​

• They respond quickly to commands and are a good match for applications that need very accurate positioning or force control.​

• They integrate neatly into modern control systems and can support features like load sensing, pressure compensation, and programmable response.​

• The flip side is more complex installation and service, so you want solid technical support if you go this route.​

Other factors that matter

On top of pump type, a handful of real-world factors will influence what actually works in your machine.

Fluid behavior

Viscosity and temperature change how the pump behaves.​  Thicker oils demand more power and can limit speed, while big temperature swings change viscosity enough to affect performance.​  Certain additives can be hard on seals or metals, so material compatibility is important, especially with specialty fluids.​  Fluid cleanliness is also critical—gear pumps will live with some contamination, but more precise units like servo pumps need very clean oil to run well.​

Environment

Where and how the pump runs also matters.​ Extreme heat or cold, particularly in places like Melbourne, calls for designs that can handle expansion, contraction, and possible cold-start issues.​ High-vibration locations or cramped installations may push you toward more robust housings, better mounts, or pumps that need less frequent hands-on maintenance.​

Suction and discharge head

• Suction head:  pump’s ability to draw oil from the tank

• Discharge head:  the pressure it can build to push oil through the system.​ 

If suction capability is marginal, you risk cavitation - tiny vapor bubbles that can eat away at internal parts and kill efficiency. You want to be sure the pump can handle the lift from tank to inlet, plus any restrictions or long runs on the suction side.​ On the discharge side, the pump must easily cover your maximum working pressure, plus line losses and any elevation differences in the system.​

When standard pumps aren’t enough

Most jobs can be handled with standard pumps, but some applications really benefit from a custom electrohydraulic solution.​  Custom-built pumps can be tuned to specific combinations of flow, pressure, and control requirements that aren’t easy to hit with off‑the‑shelf hardware.​ They can also combine several functions into one assembly, which reduces plumbing complexity, frees up space, and often improves reliability.​

Flotek works directly with customers to design pumps that drop straight into existing systems, while hitting the performance targets for that particular machine. Custom units are also a good place to add newer tech like smart sensors, predictive maintenance features (industry 4.0), and advanced controls that aren’t typically available in standard pumps.

Final Thought

When you’re ready to decide on a new hydraulic pump, start by writing down your flow and pressure targets.  Then note any special conditions like extreme temperatures, less-than-perfect fluid cleanliness, or tight mounting space.​ Flotek can help with this. Look beyond purchase price, and think in terms of total cost of ownership. A higher-end, more efficient pump can easily pay for itself with lower fuel or power use and longer service intervals.​

If your system is on the complex side, it’s worth partnering with a hydraulic specialist like Flotek (if you’re in Melbourne). They can help with sizing, potential custom tweaks, and ongoing technical support from design through to long-term operation.